Olefin polymerization catalyst and its preparation



E. s. CORNER ErAL June 16,V 1953 2,642,402

V OLEFIN POLYMERIZATION CATALYST AND ITS PREPARATIQN' 3 Sheets-Sheet 2 Filed May 20, 1950 All A' En @Vw HLP Zwama *N Nrjmv NAM Owl

. Corne r Unvenbors Eugene 5 Charles S. Lynch June 16, 1953 E. s. coRNER ETAL OLEFIN POLYMERIZATION CATALYST AND 1VT Filed May 20, 1950 @gets-Sheet 5 ,mld FMH RO@ 2,@ mm

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m 25am bzwam Patented June 16, 1953 OLEFIN PLYBIERIZATION CATLYST AND ITS PREPARATION `Eugene S. Corner, Maplewood, and Charles S.

Lynch, Plainleld, N. J., assignors to Standard Oil Development Company, a corporation of Delaware Application Mayw20, 1950, Serial N 0. 163,288

. Thejpresent invention is concerned with the polymerization of oleflns and is 'morezparticularly concrnedwith an improved polymerization catalyst `having a high activity` and a strongstructuralformation. YIn accordance with the present invention,V an improved olefin polymerization catalystislsecured `by utilizing a silica gel asthe carrier forrphosphoric acid and precalcining the silic'azigel carrier -withina critical temperature range prior to impregnation with the phosphoric acid. j 'It is well known inthe-'art to treat olens and olefin-containing streams with various catalysts,

, asfo'r example, rphosphoricacid in order to polymerizefthe olens tohigher boiling `hydrocarbon constituents. In general, the feed streams comprise .normally lgaseous olefins, such.` as 1 ethylene, propylene, butylenes, 4pentylen'es and mixtures thereof, which are polymerized to hydrocarbon utilized "as `feed stocks,it is generally preferred tohaveparainic diluents present in the range of from abo'ut'f40% to 90% byweight in `order toreduce-the formation of carbonaceous deposits on the catalyst `and to provide better temperature control `in `the catalyst bed. These phosphoric acidwcatalysts 'are usually deposited on solid` carriers,l as for example, diatomaceous earth,i.kieselguhr, silica gel, and the like. In generaLthese `catalysts `are satisfactory for securing the polymerization of the volefins in the feedstream.` However, there existcertain inherentdisadvantages withfrespect `to theirwuse inv that 'the activities of the catalysts `-are Vnot as high as it--isv desired. A particularly undesirable characteristic of catalysts lheretofore used -isgthat their structural strength is relatively weak, `resulting injpremature failures and disintegrationof `the same.`

Itis `wel-l known that solid, phosphoric `acid type oleiin polymerization catalysts tend to soften and disintegrate in conventional chamber `and tubular olefin polymerization units. The `loss of mechanical strength with resultant disintegration causes ,pressure build up `in the unit and poorrcontacting due to feed channeling within `theabed. Inasmuch as the mechanical failure of .these `catalysts, frequently necessitates catalyst replacement, even though intrinsic 'activity is unaffected, itis highly important in order to "take advantage of the excellent activity of phosphoric acid-silica base catalyst, that catalysts of good strength characteristics be prepared.

vTl'ie improved catalysts ofthe present inven-" tion maybe employed in 4conventi'onal l'fixed bed Y bed tube process.

` constituentswhich boil inV thelrange below about l 420."1l'.` Although 100% olenic streams maybe `tains catalyst fines.

9 Claims. (C1. 252-435) f n Y l V l A tube units. However, since they are of a greater strength thevcatalysts of the presentinvention are particularly `desirable for use in slurry type polymerization operations and in Vlluid `catalyst polymerization processes.

The present invention may be morereadily uriderstood by` reference Yto the attached drawings illustrating embodiments ofthe same. Figure l illustrates a slurry type-polymerization operatiom while `Figure .2. illustrates r .a .fluid catalyst polymerization process.

Referring specifically to Figure l, afeed stream, which for the purpose ofA illustration isassumed to be a liqueable normally gaseous hydrocarbon stream containing` rllolelins, is` passed rthzrougli` heating zone lfby means of'linef2. In this zone,`

the `feed stream isheated to the desiredtempera- Vture andwithdrawn-by means of line`3. The

heated stream, which `for the purpose of illustrationis assumed-to be at a temperature in the rangefrom about 400.F. to 500 F., is introduced into the bottom of reaction chamber 4. O perations are so conductedas to provide a hindered settler catalyst bed in the lower area of reactor 4. Inaccordance with the present invention, the catalyst bed comprises phosphoric acid deposited on silica gel. The `upper area of reactor 4 comprises asettling zone wherein the catalyst particles tend to settlefrom the liquid material llowingupwardly in zone 4. For the purpose of illustration, it is assumed that thepressurein reactionzonejtl is about 1000 lbs.V per squareinch.

V,'Ihe product stream is -withdrawn from the top of reactor 4 by means of line 5 which stream con- This stream is introduced into a slurry 4fractionation zone 6 `which is maintained ata pressure preferably in the range from about lbs; to 200 lbs. per square inch. A product stream completelyfree of catalyst lines is removed overhead from zonet by means of line 'l and passed into accumulation zone `8. `A polymerized product comprising `hydrocarbon constituents boiling in the motor fuel boiling range is withdrawn 4from `zone 8 by means of line 9: and further refined or handled ,as desired. `Under certain conditions, it maybe desirable to recycle l means of `line l0.

a portion of the product stream into zone 6 by- The desired temperaturein zone 6, which may vary from about to F. andhigher, is maintained by any suitable means, as for example, by a reboiler arrange-A ment. A recycle slurry stream is withdrawn from the bottom off zone-6 by means of line I I. A portion of this stream is :passed through heater I2 Figure N3` illustrates a lixed` tem by means of purge line I1. Water may be introduced into the system by means of line I9.

Referring specically to Figure 2, a feed stream,

which for the purpose of illustration is assumed Y to be liquefiable normally gaseous hydrocarbons, is introduced into the system by means of -line 2|! and passed through a preheater zone 2I. These gases which for the purpose of illustration are assumed to be in the temperature range from about 250 F. to 300 F., are Withdrawn from zone 2I by means of line 22 and introduced into the bottom of a reaction zoney 23, wherein a catalyst is maintained inthe fludized state. For the purpose of illustration, it is assumed that-reaction zone 23 is maintained at a pressure 'of about 300 lbs. per square inch and at a temperature of about 500 F. The catalyst comprises phosphoric acid on silica gel which may contain a relatively small amount of nickel phosphate or other added promoter. The catalyst particles have diameters in the range from about to about 180 to 300 microns, and preferably have diameters in the range from about'20 to 120 microns. The linear velocity of the upflovving gas is in the range from about .5 to 10 ft. per second, whereby the catalyst particles are maintained in a fluidized state. The upper section of the uidized catalyst bed is maintained at point A in th-e reaction zone. During the operation, water may be added continually o-r periodically to a point'in the catalyst bed by means of line 24. The reaction product is remo-ved from the top of zone 23 b-y means of line 25'after passing through cyclones or equivalent means 26. These cyclones serve toi remove catalyst particles in the-gas which are returned to the catalyst bed by meansof line 21. The re- .,action gases are introduced into the bottom of a quenchtow'er 28.' These gasesfiow upwardly and countercurrently contact a downflowing quenchl liquid which is introduced into the top of zone 28 by means of line 29. The quench liquid serves to cool the' reaction gases thus preventing anyA further reaction and to remove the last traces of catalyst particles from the gases. The slurry is removed from the bottom of zone 28 ,byomeansY of line 30. A portion of the slurry isreturnedto zone 23 by means of line 3I at a point above `the catalyst bed. The remainder of the slurry isv passed Vthrough cooler 32 and recycled to the top of quench tower 28.

The product gases comprising hydrocarbons boiling in the'motor fuel boiling range are removed overhead fromzone 28 by means of line 33, passed through'cooler 34 and removed from the system by means of line 35. .Thesefgases are condensed and further refined and handled as desired. Spent catalyst is removed-from the system by withdrawing the same from the bottom of zone 23 by means of line 36. A Y

Referring specically to Figure 3, illustrating afixed bed operation', feed gases comprising C3 and C4 olens are introduced into thesystem by means of line 50. Hydrogen sulphide is removed from the gases in zone 5I and mercaptansre-l moved in zone 52 by any suitable means The feed gases are passed through heat exchanger zone, 53, preheated to the desired temperature in zone 54 Vand, then introduced into reactor 55.

Water may be added to the feed gases in order to helpy maintain catalyst activity by means of line 56. The feed gases flow downwardly in zone 55, are removed by means of line 51 and introduced into the topof reactor 58. Since the polymerization reaction is highly exothermic, and since reactor temperature controlis very important in terms of catalyst life and polymer quality, the desired temperature isV maintained in the reactors by means of Water circulation which is introduced into reactors 55 and 58 by means of lines 59 and 60 respectively. Water or steam is withdrawn from the respective reactors by means of lines-6I and 62. VThe tubes of reactors 55 and 58 contain polymerization catalyst comprising phosphoric acid deposited on a silica gel carrier.

The reactor product is withdrawn from reactor -58 by means of line 63, passed through heat exchanger 53 and introduced into stabilizer 64.

Hydrocarbons boiling in the range of propane 1.

and lovver are removed overheadfrom stabilizer 64 by means of line 65fwhile the higher boilingproduct is removed by means of line 66 and in troduced into a debutanizer unitV 61. Butane is removed overhead from Zone 61 by means of line 68 while the polymer product is removed' by. means of line 69. This polymer product stream may be fractionated inv order to secure the de'' or further r'ened and sired boiling range product handled as desired. The present invention is tion. The catalyst may also comprise from .about .5 to 5% of a salt fof copper nickel, manganese,

cobalt iron, cadminum and the like.

The calcination temperature used prior to impregnating With phosphoric acid should not be lower than about 400 F. nor higher than about 1400 F. A preferred temperature of calciningV or drying the silica gel before impregnation isv in the range from about G-to 1250 F.

The silica gel may be prepared by any conventional procedure. One method is tofadd sulfuric acid to a solution of sodium silicate resulting in the formation of the sol which in turn sets to a gel. The gel will contain from about 80 to 90% of Water and is preferably washed in `order to free it of ionic contaminants priorA toV calcining.,

After calcining the silica'V lgel preferably at a. temperature in the range from 800r F..to 1250 F., the calcined gel is pulverized and ball milledlwthz phosphoric acid.

phosphoric acid. The promoter salt if used may be anysalt,'as for example, the phosphate, the' l nitrate, the sulphate, the chloride, the fluoride? and the oxide.

The amount of phosphoric acid employed with respect to the silica gel may be varied appreciably. Howeven it is preferred that the 'concen-l tration of the phosphoric acid 'be in the range. froml about 50 to 90% by weightof total catalyst;L

preferably in the range froml'15 to 85% by Weight` calculated as I-IaPO4.

perature in the range betweenabout 375 `Foto 425 F. Averydesirable,ernstgemeinte,

broadly concerned with an improved polymerization process utiliz--n ing phosphoric acid catalystV supported on silica gel which has been calcinedzprior to` impregna-f.,

The 'amount ofpromoter.

salt may vary appreciably if utilized `as for ex-r,

ample in the range fromabout 1 to 10%j- The wet slurry is preferably dried atatemeguali-na -EXAMLE various phospnnc ,aeidjsiiibalgerfcatalysts Wereprepare'clbyladding i s'odiiinn 'silicate' solution to'sulfuricacidiiwashing with Water to remove Aoccliided sodium and sulphate ions and then dried at various ,temperatures and pulverized. '.Ifhevarious drying temperaturesused before `impreg- 1800%l,.` lAt temperatureszabove 400 F. aninitial dryingstep` of 400 F. ,was `employed prior "to fdrying `attemperatures ofi1000vtov1800 F.. :The avarious dry silica gel portionswere then ball milled `With phosphoric acid, dried .at :a temperature-,in the frangedom `about 375 F. `to 425 F. `and. then calcinedcat-SOO" Thevarious' catalystsfwere then'used Von a feed stream containing 47% C3 and C4 olens present in equal volumes in a polymerization operation employing a temperature of 450 F. and a thousand pounds per square inch pressure. The results of these operations are listed in Table I. a v

Table I.-E1ect of4 calcining SiOz gel base before Y A adding II3P04 [80% HaPOl 20% S102; 47% O3=+C4=;450F.; 1000 p. s. i. g. 6.7 v. v./ hr. 140 F. H2O saturatoiz] Olen Conversion, SiOz Carrier Cat. Age; Gal.

Polymer Per No Heat Cat. 250 400 l, 000 `1, 472 1, 800

' F F. F. F. F.

96 `04 93 92 (l) L-- Failure 92 92 91 91 30... 91 91 90 87 40.. 89 90 87 81 50 87 E118l 86 1 The catalyst softened up when calcining at 1,800 F.

Table II [Propylene-butylene feed, 450 F.; reaction temp., 1,000 p. s. i. g., 36.7 v./v./hr.; Water saturator temp., 140 F.]

SiOz CalciningaTemperature 1 `Catalyst strength inferior.

From the above itis apparent that a considerable increase in catalyst strength is secured by calcining at temperatures above 400 F., preferably at a temperature of about 1000 F.

i The 4rtime :of drying for 'calcining' `the silica gel before impregnation With phosphoric acid may var-yappreciably, Vas for fexampleifrom 4 .to '48 hours and higher. "HoWeverQit is fpreferred to' employ a two-stage drying operation Wheniemy ploying the preferred calcining' temperature of 800 to 1'0'00. AUnder `these `'conditions `the silica gel isffirst dried atla -temper'ature of about 250 then calcined at'latempera'turein-theIrange from 80`0fto 100`0- v'for aperiod of from"2 to 10hours.

"The-feed streamsfor the polymerization operation are rpreferably normally` gaseous hydro'- carbonscontainingfolens. Various diluents may i bepr'esent. A preferred feed 'streamcomprises ne'vvhich contains Vfrom about30 to 50%` of olens. Although-the polymerization *temperature may be inthe rangefrom about 300]Fgto 900'-F'., a preferred polymerization temperature is in the range from about 400 "FQ to 500;F.` Polymerization pressures likewise may vary Widely",4 asfor example, inthe; range fromaboutfl) lbs. per squarek inch gauge to 1500 lbs. persquare inch gauge. Preferred pressures are in the range from about 300 to 1000 lbs. per square inch gauge. Feed rates may vary depending upon other operating conditions. In general, the feed rates are in the range from about .5 to 15 volumes of fliquefied gas per volume of catalyst per hour.

f VIn order to maintain the activity of the catalyst at high levels for long operating periods, it may be necessary to inject continuously or at frequent intervals into the reactor containing the catalyst,

perature in therange of '800-1000 `mixing with said acid.

small'amounts of water in order to prevent dehydration of the catalyst. This water may be added in one of several Ways. It may, if desired, be pumped directly into the inlet of the catalyst bed or metered streams may be employed. Another alternative is to contact the liquefied feed with water maintained at a suitable temperature to saturate the feed with the desired quantity of water. If the latter method is employed, the Water for feed saturation is held at a temperature of from about F. to 180 F. depending on operating conditions. An'amount of Water equivalent to from .1 to 2 gallons of Water per thousand gallons of` feed is required.

`Having described they invention it is claimed:

1. Improved olen polymerization catalyst composition consisting esentially of a phosphoric acid deposited on a silica gel base, said catalyst having been prepared by heat treating a silicaV gel base at a temperature in the range of 400-1250 F. for at least 2 hours, forming a mixture of the heat treated silica gel and a phosphoric acid and pulverizing said mixture, drying the pulverized ymixture at a temperature in the range of 375-425 F., and calcining the dried mixture at a temperature in the range `of 600-1000 F. to form an active polymerization catalyst containing in the range of `50-90% by weight of phosphoric acid.

2. A catalyst composition as in claim 1 wherein said silica gel base is heat treated at a tem- F., before 3. Acatalyst composition as in claim ll wherefin said silica gel Ibase is heat treated at a temperature in the range of about 250 to 400 F., for a period inthe range of about 10-60 hours and then further heat treated at a temperature in the range of about 800-1000 F. for a period in the range of 2-10 hours before mixing with said acid.

4. A catalyst composition as in claim 1 Where- 7 in the'saidsilieagel base is heat treated for a time in the rangeof :about 4-48 hours.

5. A process for making an improved olen.

polymerization catalyst consisting essentially of phosphoric acid deposited on a silica gel base which includesl the steps of ,forming a silicagel ,I

base, heattreatingsaid silica gel, base at a Vtem-- perature in the range of 4009-1250 F.1,for 'at least Z hours, forming a' mixture ofthe heat treated silica gel and -a phosphoric` acid `and pul- Verzing said mixture, drying the pulverzed mixture at a temperature in the range of 375-425 F., and calcining the dried mixture at a temperature in the range of `600" to 1000 1i'. to form an active polymerization catalyst containing in the range of 50-9 O% lby weight ofphosphoric acid.

6. A process as defined byk claim 5 wherein l said silica gel base is heat treated at a temperature in the range o f 800-1000f F. before mixing with saidgacid. Y A

, 7. A process as dened .by claim 5 wherein said silica gel base is heat treated ata temperature in the rangeof about 25W-400 F. for a said dried mixture is calcined in a'temperature in the range of 'about 700-900 F.

f References Cited in the file of patentV UNITED STATES PATENTS A ,Y Date-V Number Nam-e 2,120,702 Ipatieff et al. June 14, 1938 2,121,258 Osterstom et a1. June V21, 1938 2,129,733 Fulton et a1. Sept. 13, 1938 s 2,447,599 Schmerling Aug. 24, 1948 2,496,621 Deery Feb. 7 1950 2,547,380 Fleck Apr.` 3,11' 195,1-

EUGENE S. CORNER; v CHARLES S. LYNCH. 

1. IMPROVED OLEFIN POLYMERIZATION CATALYST COMPOSITION CONSISTING ESSENTIALLY OF A PHOSPHORIC ACID DEPOSITED ON A SILICA GEL BASE, SAID CATALYST HAVING BEEN PREPARED BY HEAT TREATING A SILICA GEL BASE AT A TEMPERATURE IN THE RANGE OF 400*-1250* F. FOR AT LEAST 2 HOURS, FORMING A MIXTURE OF THE HEAT TREATED SILICA GEL AND A PHOSPHORIC ACID AND PULVERIZING SAID MIXTURE, DRYING THE PULVERIZED MIXTURE AT A TEMPERATURE IN THE RANGE OF 375*-425* F., AND CALCINING THE DRIED MIXTURE AT A TEMPERATURE IN THE RANGE OF 600*-1000* F. TO FORM AN ACITIVE POLYMERIZATION CATALYST CONTAINING IN THE RANGE OF 50-90% BY WEIGHT OF PHOSPHORIC ACID. 